WCN Autumn 2014

OFFICIAL NEWSLETTER OF THE INTERNATIONAL WIRE & MACHINERY ASSOCIATION WIRE & CABLE NEWS Autumn 2014 - issue No 51 www.iwma.org CN

demanding fields such as automotive.

Needless process described leads to a production slowdown and delays can even amount to several hours in case of CV lines. In order to maximise efficiency and eliminate non-productive time, SAMP has recently developed Chameleon, a revolutionary solution that allows the cable type changeover from a striped cable to a non-striped one, and vice-versa, in just a few seconds, without stopping the production line and disassembling the extrusion head. various extruders are all managed by a single device, which conveys them in the right direction depending on the type of cable to be produced. A simple gesture is enough to control the final melt flow directions. technology allows the production of perfectly homogeneous cables, since all the insulation materials are obtained by working at the same temperature and the same pressure level. Moreover, the same distributor is used when producing striped and non-striped cables, so that no extra device is needed for the changeover. Chameleon technology is suitable for all SAMP extrusion heads, including the more sophisticated like the TX6V, which is equipped with the “0-scrap” quick change colour system for the cable stripe, and the TX6V2, where the “0-scrap” system can be applied both to the stripe and the insulation. All parameters can be easily managed via the SAMP Supervision and Control Unit, through which production can be automatically programmed and a number of statistical and graphical analyses can be carried out. to say, the By means of this system, the materials flowing from The Chameleon

S S Chameleon technology allows production of perfectly homogeneous cables

Cutting edge Chameleon

1. Stop the production line

In a constant effort to provide cost-effective solutions and innovations to the cable industry, SAMP continuously invests in research and development. The latest and most important innovation is the Chameleon technology, a breakthrough solution for cable type changeover without production stop and speed limitations. Like a chameleon with the ability to change colour fast and frequently, the brand new solution guarantees maximum flexibility, efficiency and reliability throughout the extrusion process. Traditionally, when changing a cable type, when going from a striped cable to a non-striped one, the procedure to be followed is rather long and includes a number of steps:

2. Cool down the machinery

3. Open the extrusion head

4. Replace the distributor or ring that creates the stripe on the cable with a similar device allowing the application of a single layer without stripe

5. Reheat the machinery

6. Start the production

This rough outline describes what takes place in the majority of the cases. SAMP has intentionally avoided to mention any other unconventional, home-made attempt to avoid production stop, since these cannot guarantee product homogeneity and therefore do not meet the market requirements, especially in

SAMP SpA – Italy Email: info@sampsistemi.com Website: www.sampsistemi.com

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WCN Carl Bechem GmbH.....................................................p16 Beta LaserMike..............................................................p11 BWE Ltd / TF Kable .........................................................p4 Cimteq Ltd......................................................................p18 Condat SA.......................................................................p23 data M Software GmbH.............................................p13 Eder Engineering GmbH..............................................p8 FIB SA...................................................................................p3 Gauder Group................................................................p23 GEO-Reinigungstechnik GmbH.............................p16 GER SA.................................................................................p2 Gürfil Sanayi ve Elektronik Cihazları Pazarlama A.................................................................p17 Heinze & Streng GmbH.............................................p20 Jiangsu Jiacheng Technology Co Ltd......................p7 lune Prozesstechnik GmbH......................................p10 Maillefer Extrusion OY................................................p20 Marldon Group Ltd......................................................p13 Metalube Ltd....................................................................p9 Maschinenfabrik Niehoff GmbH & Co KG..........p20 OrmistonWire..................................................................p4 PW Hall Ltd........................................................................p8 Polifibra SpA...................................................................p19 PressureWelding Machines Ltd................................p6 Queins Machines GmbH.......................................... p23 Rosendahl / Nextrom OY.............................................p5 SAMP SpA..........................................................................p1 Rolf Schlicht GmbH........................................................p5 Shanghai KechenWire & Cable Machinery Co Ltd ..............................................................................p8 Shanghai Singcheer Technology Co Ltd............p21 Shanghai Kingway Technology Group Ltd...........p3 Siebe Engineering GmbH.........................................p19 Sikora AG.........................................................................p21 South AfricanWire Association..............................p10 Joachim Uhing & Co KG...............................................p2 Wire Association International ..............................p18 Zumbach Electronic AG............................................p17 CONTENTS Technical Article. ... 24 Wire & Cable News Katsuoka, and Kota Doi, Tokai University; and Yasutomo Takemoto, Sumitomo Denso Co Ltd, Japan Wire & Cable News is published twice a year by the IWMA. All the text and illustrations in this publication are copyright protected. Copying of the contents by photographic or electronic means is forbidden without the publisher’s written consent. The publisher, agents, printers and contributors cannot be held responsible for the accuracy of claims printed or inferred in the editorial or advertisements published in this, previous or subsequent editions. The publication in this newsletter of Brand Names, Trade Names and Trade Marks and similar does not imply that these may be used elsewhere. IWMA 46 Holly Walk, Leamington Spa, Warwickshire CV32 4HY, UK Degradation of mechanical properties of drawn copper wire by occurrence of dynamic recrystallisation By Kazunari Yoshida, Naoyuki

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Uhing linear technology in action in all its glory

The RG rolling ring drive is possibly the most famous Uhing invention, and this is reason enough to present these products online around the world. The rolling ring drive comes in countless variants and with a great range of accessories. The linear technology video shows the RG in the ‘moving spool’ winder and also with an electronic controller.

The linear drive nut RS comes with features and areas of applications as flexible as those of the rolling ring drive. It can be operated even in dirt-laden areas and meets the high requirements of the food industries. The same also applies to the Easylock quick clamping system that develops high retaining forces on plain shafts. It is independent of the direction of rotation, vibration-proof and maintenance-free. Short change-over times are ensured by one hand operation. This property also applies to the Uhing U-Clip that securely fastens coils, rollers or cover parts on plain shafts. Timing belt drives featuring high thrust forces, robustness and long service life complete the Uhing range of linear technology products. These guide systems have bases made of rigid and torsion-resistant aluminium sections. Attachments can be mounted and T-slotted nuts inserted into the slots of the base profile. technology products not only convince by their function but also by their design. The product video available on the Uhing website clearly demonstrates this. The Uhing linear

S S The RG in the moving spool winder and with electronic controller

A feasible accessory for the rolling ring drive is the non-contact FA flange detecting system. It detects the coil width and the type of the coil flange automatically and matches the reversal points of the rolling ring drive accordingly. A laser sensor system checks the winding pattern continuously and triggers the reversal as soon as the material to be wound reaches the maximum height defined in the control software.

Joachim Uhing & Co KG – Germany Email: info@uhing.com Website: www.uhing.com

South America and European deals GER SA, of Nessonvaux, Belgium, recently sold several complete

production lines for PC wire and PC strands to customers in South America and Eastern Europe. Those lines comprised heavy duty rod breakdown machines, indenting units, low relaxation equipment, induction furnaces, coiling and coil handling machinery. A total of 2140-feet open top containers were loaded and shipped out by the second-hand machinery specialist.

Tel : +44 1926 834680 Fax : +44 1926 314755 Email : info@iwma.org Website : www.iwma.org Autumn 2014 www.iwma.org

GER SA – Belgium Email: ger@ger.be Website: www.ger.be S S Part of the shipments recently send out by GER

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Online help for customers

DIARY OFWORLD CLASSWIRE & CABLE EVENTS FOR BUSINESS,TECHNOLOGY, EDUCATION & NETWORKING

2014

OCTOBER

Wire & Cable India 2014 Mumbai, India Exhibition

 Messe Düsseldorf GmbH

28-30

Email: ryfischd@messe-duesseldorf.de Website: www.wire-india.com

S S A screenshot of the new system from FIB

NOVEMBER

An online frequently asked questions and personalised documentary platform has been developed to give a 24/7 access to allow a better support to FIB’s users. Shared information, tips and tricks, structured proper documentation and tracking support are part of the system. Many other features are in development such as maintenance calendar and maintenance logbook. maintenance teams in the handling of technical documentations, tunings, set-up and for the coordination between them. To take advantage of the system contact Joseph Demonchaux on j.demonchaux@fib.be This approach will help the production and Research and development pays off Shanghai Kingway has been concentrating on the technical research of dies for the wire drawing industry, and is dedicated to expanding research and development for the wire and cable industry. ISO 9001 and SGS certified, Kingway monitors quality control all the way from raw material through the production process of dies. Shanghai Kingway Technology Group Ltd – China Email: martinding@188.com Website: www.kingwaytechnology.com FIB SA – Belgium Email: info@fib.be Website: www.fib.be

 IWMA

IWMA Dinner Dance Royal Garden Hotel, London, UK Event

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Tel: + 44 1926 834680 Email: info@iwma.org Website: www.iwma.org

2015

FEBRUARY

IWMA AGM and Member’s Lunch The Mere Golf Resort & Spa, Knutsford, UK Event

 IWMA

Tel: + 44 1926 834680 Email: info@iwma.org Website: www.iwma.org

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APRIL

Interwire 2015 Atlanta, Georgia, USA Exhibition

 WAI

28-30

Email: info@wirenet.org Website: www.wirenet.org

MAY

wire Russia 2015 Moscow, Russia Exhibition

 Messe Düsseldorf GmbH

12-15

Email: ryfischd@messe-duesseldorf.de Website: www.wire-russia.com

SEPTEMBER

 Messe Düsseldorf GmbH

wire Southeast Asia 2015 Bangkok, Thailand Exhibition

Email: beattrice@mda.com.sg Website: www.wire-southeastasia.com

15-17

OCTOBER

wire South America 2015 São Paulo, Brazil Exhibition

 Messe Düsseldorf GmbH

6-8

Email: niemannh@messe-duesseldorf.de Website: www.wire-south-america.com

NOVEMBER

CabWire 2015 world conference Düsseldorf, Germany Innovations driving worldwide wire & cable markets Conference

 IWMA

Tel: + 44 1926 834680 Email: info@iwma.org Website: www.cabwire.com

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 IWMA

Acelor/Mittal rod mill Duisburg, Germany Plant tour

Tel: + 44 1926 834680 Email: info@iwma.org Website: www.cabwire.com

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First SheathEx order in Europe for BWE

reliable and economic solution for power generation and transmission systems.” As well as this first contract in Europe, BWE has supplied a further six lines to cable companies in China. All are in full production and these cable manufacturers are now able to secure large cable contracts based on the aluminium sheath being ‘seamless’. With no weld, the cable sheath is now reliable against the ingress of moisture. By using aluminium instead of lead, the cable is much lighter, environmentally friendly and less harmful to health. An aluminium sheath has good mechanical properties making it stronger and lighter than lead with higher conductivity. TF Kable also has a BWE Conform™ 350 machine. This machine is used to extrude round and sector shape solid aluminium conductor (SAC) from 2 x 9.5mm diameter aluminium rods.

S S TF Kable has invested in BWE’s SheathEx™ technology

voltage (HV) and extra high voltage (EHV) cables. TF Kable is now able to extrude a ‘seamless’ (no weld) aluminium sheath over cable. The aluminium sheath is produced from two 12mm diameter aluminium rods. The sheath is corrugated inline (helical or annular) to improve flexibility. Mr Marcin Szymañski, vice president high voltage systems, said: “This investment reflects consistent execution of TF Kable’s strategy to expand in the EHV business. With our new SheathEx line we are able to serve our clients with a modern, darkened 0.125mm diameter wire, which was used throughout the series until the Andersons moved into live-action productions in the early 70s. ‘Filmed in Supermarionation’ uses unseen archive footage, new interviews and clips from the shows to tell the story of Gerry and Sylvia Anderson’s legendary TV productions in greater depth than ever before. Directed and produced by Stephen La Rivière, the definitive documentary presents the story of how series such as ‘Thunderbirds’, ‘Stingray’ and ‘Captain Scarlet and the Mysterons’ were brought to audiences around the world using pioneering puppetry techniques and special effects. manufactured and

Tele-Fonika Kable SA (TF Kable) is the first company in Europe to invest in BWE’s SheathEx™ technology. Based in Poland, TF Kable is the largest cable company in Central and Eastern Europe delivering its products to more than 80 countries worldwide. In 2013, the company was awarded the Special Honorary Distinction for its 500kV cable produced at the Bydgoszcz Plant. TF Kable’s development and expansion programme included the purchase of the SheathEx line, which allowed the company to consolidate its position in the ranking of manufacturers specialising in the production of high

BWE Ltd – UK Email: info@bwe.co.uk Website: www.bwe.co.uk TF Kable – Poland Email: info@tfkable.com Website: www.tfkable.com

It’s all go for launch for Ormiston Ormiston Wire provided wire for a new documentary film about Gerry and Sylvia Anderson 50 years after providing innovative wire for the iconic children’s television show It developed, supplied a chemically

“‘Thunderbirds’ is an iconic British television series and is loved by different generations across the globe,” said Mark Ormiston, managing director. “We were delighted to support the production of this documentary film 50 years after we first provided Gerry and Sylvia Anderson with wire for the marionettes.” will premiere at the BFI later this year ahead of a general release in autumn 2014. ‘Filmed in Supermarionation’

‘Thunderbirds’. The company supplied the makers of the documentary, titled ‘Filmed in Supermarionation’, with wire for the filming of new ‘Thunderbirds’ sequences. The company was initially approached by AP Films in the 1960s to help solve the technical issues in filming marionettes for the original ‘Thunderbirds’ show. The innovative solution was a very thin yet durable metal wire filament to manipulate the puppets, which was darkened so there was no reflection, therefore making it as invisible as possible.

Ormiston Wire – UK Email: info@ormiston-wire.co.uk Website: www.ormiston-wire.co.uk

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Fine-tuning loose tube line Staff from Rosendahl and Nextrom teamed up for what they describe as a ‘ground-breaking’ moment in fibre optic cable production after they redesigned, rebuilt, tested and fine-tuned the results for the loose tube line.

• Better process feedback during production • Typical line speed 600m/min for standard loose tube types • New development of the crosshead series RX for optimised material flow in the melt distributor, in conjunction with a linear jelly needle guiding system for easier handling • New generation of pulley clenching capstan SCC100 for accurate post shrinkage and EFL control, especially for dry tubes • Improved online EFL measurement system Rosendahl – Austria Email: office@rosendahlaustria.com Website: www.rosendahlaustria.com

optimisation of each step of the production process. In order to improve cable performance and reduce the costs of the final product, many technologies and devices have been invented to minimise optical loss, increase production speed and allow more flexibility in the manufacturing process. New developments made especially for the loose tube process include: • Improved high speed fibre pay-off design with reduced footprint for space saving • Special processing unit of the ROEX extruder to optimise the process ability of typical material used for loose tube production • Optimised and space saving cooling trough design – safe up to 9.5m in line length In the machine there is a fully automatic and maintenance-free filter system consisting of compact filter elements of large dimensions, which are cleaned off by a special process. No blowing-in of compressed air is necessary. Thanks to this filter system a strong and constant vacuum is generated in the machine, so that no powder escapes into the ambient atmosphere. If there is not enough space in the line to place the machine Rolf Schlicht delivers a free-standing dusting chamber which is connected to the machine by hoses. For an extremely fine powdering of slow running products it offers as an option a fine dosing device to make sure that only a breath of powder is adhering on the strand. An automatic 90l powder refilling hopper, a powder flow indicator giving an alarm in case no powder flows through the guns, an automatic adjustment of the electrostatic and the pneumatic in compliance with the extrusion speed, and an interface to connect the machine to the line can be supplied as accessories.

S S The loose

tube line from Rosendahl

The

current

trends

in

fibre

Nextrom OY – Finland Email: info@nextrom.com Website: www.nextrom.com

optic

cable

manufacturing

are

all

connected

to

the

general

RSC powder coating machine The machine model RSC was designed to powder hoses, profiles, strips, bands and cables evenly, finely dosed and absolutely dust free with powders like talc, stearate, lac powder, swellable powder, graphite, etc. Rolf Schlicht delivers machines for the smallest product diameters up to 200mm and bands up to 500mm width.

By the electrostatic charging of the powder, a strong adhesive power on the product and a very even layer on the surface are reached. The electrostatic also ensures that no powder falls from the product outside of the dusting chamber. The company can also deliver machines with just two or four powder nozzles depending on the application. For powdering hoses, profiles and bands made of rubber, it is mostly the machine without electrostatic that is used. In the machine there is a fluidised powder hopper out of which the powder is sucked by pneumatic venturi pumps and blown through the guns or nozzles onto the product. For an optimal adjustment of the powder quantity the power of the electrostatic charging can be altered from 0-100kV, as well as the powder quantity and speed of the dust cloud. Depending on the product the powder gun can be equipped with different rebounding plates.

Rolf Schlicht GmbH – Germany Email: info@schlicht-gmbh.de Website: www.schlicht-gmbh.de

S S The RSC powder coating machine

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Three new board members

He looks forward to more involvement with the IWMA and working with the executive board for years to come. Martin van der Zwan began working in the cable industry in 1977 at the BICC Wrexham factory. He served his time there working originally within the factory and then moved to work study and then material control. He retired from Pirelli (now Prysmian) in 2008 and set up his own company called Cable Tapes UK Ltd with Paul Haines, his business partner, and to date has been very successful. He is a great supporter of the association’s educational trust and believes it should strive to encourage young talent to come into the industry, ensuring it stays at the forefront of technology. He now feels that his knowledge and experience of the cable industry could be used to support other companies within this area with advice and assistance where required. including the P1500 rod welder for joining large rod sections up to 30mm diameter. Recent innovations include the portable HP100 and HP200 machines, which provide effortless welds on wire and strip 1mm to 5mm and 2mm to 6.5mm. All PWM machines and dies are precision engineered in-house to stringent quality standards by PWM’s own team of skilled engineers and technicians. PWM has a worldwide network of experienced agents who, together with its UK team, provide fast and efficient on-site support with full back-up and after-sales service. ensures that it continues to offer wire and cable manufacturers the most advanced and comprehensive range of cold welders in the world. To explain the cold weld process, the company recently developed a series of videos demonstrating the technique. PWM’s on-going research and development programme

wire and cable machinery sector throughout the Far East and North America, commencing in 1990 with Nokia-Maillefer followed by positions at both SAMP Sistemi and Niehoff Endex North America. in international market development he is looking forward to supporting the IWMA in all its existing and emerging programmes, designed to further the interests and opportunities of the membership at home and abroad. Mr Dawson has been involved with the wire industry since his early years, and joined Whitelegg in 1992 after travelling widely and working at Emil Jaeger Maschinenfabrik in Germany. Although having had no technical training, Glyn’s keen mind allowed him to master the ranges of CNC controlled machines and he commissioned these all over the world. With a strong background

The International Wire and Machinery Association’s executive board has been strengthened following the appointment of three new members at its AGM in February.

Don Neville, managing director of RichardsApex Europe Ltd; Glyn Dawson, managing director of Whitelegg Machines Ltd; and Martin van der Zwan, co-owner of Cable Tapes UK Ltd, were all appointed at the meeting prior to the “Meet the Industry” luncheon at The Mere Resort, near Manchester, UK, on 12 th February. Prior to his current position Mr Neville worked extensively in the

PWM celebrates 30 years of service

S S Staff of PWMand guests at the 30 th anniversary celebrations at wire 2014

PWM’s first machines were small, manually operated cold welders for joining fine wire and strip. The M10, M25 and M30 models for wire sizes 0.1mm to 1.8mm are all still produced today. gradually expanded its range and introduced larger, powered cold welders, Over the years, PWM

British (Pressure Welding Machines) Ltd celebrated 30 years of service to the wire and cable industry at wire 2014. PWM, based in Kent, UK, designs, manufactures and supplies high-performance cold welding machines and dies to wire and cable manufacturers worldwide. company PWM

PressureWelding Machines Ltd – UK Email : pwm@btinternet.com Website: www.pwmltd.co.uk

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Worldwide exports Jiangsu Jiacheng Technology Co Ltd was founded in 2001 and manufactures high-speed wire drawing machines, rigid frame stranding machines, annealing and tinning machines, double twist bunchingmachine and extruders. The company’s own manufacturing plant has been making processing equipment, machine bodies and other key components over the last ten years. In addition to its ISO and CE certification, the company has a number of awards for high quality machine design. exported to America, Brazil, Russia, Korea, Japan, Vietnam, India, Iran, Pakistan, Bangladesh, Malaysia, Kenya, Syria, Dominica, Brazil, Peru, Egypt, etc. Jiangsu Jiacheng Technology Co Ltd – China Email: shelleysun@jsjcjx.com Website: www.jsjcjx.com Calling all members Show customers and competitors alike that your company is serious about promoting new technology, education and growth within the wire and cable industry by including an ‘IWMA Member’ badge on your company website home page, email signature and stationery. IWMA’s Educational Trust Fund and its Travel Award scheme, the association actively encourages the gaining of new skills and experience for future rising stars in the industry. The electronic file is available from the IWMA office in a variety of electronic formats to help promote your business. Remember to follow the IWMA LinkedIn page to ensure you are kept up to date with all activities, whether it is announcements about exhibitions, conferences and events or the education trust, as well as members’ news. LinkedIn to us! Jiacheng’s products are Through both the

Stalwart service from two board members

Two members of the International Wire and Machinery Association retired from the executive board at the annual general meeting in February.

the association over the years and will, without doubt, miss the many friends I have made during my time at the IWMA,” he said. Mr Dawson’s place on the board has been taken by his son, Glyn, who will continue the tradition of Whitelegg Machines being a long-standing supporter of the IWMA. The company was one of the original founding members in 1970. IWMA’s chairman Mr Steven Rika said of the retirements “I would like to thank both Terry and Colin on behlaf of the board and our members for all their efforts over the years.” S S Colin Dawson, right, is thanked for his service by chairman Steven Rika LEONI AG, committed as a keynote speaker and Acelor/Mittal preparing to host a visit for delegates to its rod mill in Duisburg on Wednesday 4 th November. There will also be an event at a downtown Düsseldorf location on the Tuesday evening where delegates will get the chance to network and socialise. If you would like to be involved by presenting a paper at this exciting event, then please forward by email a short abstract of no more than 50 words to the IWMA office at info@ iwma.org There is also a variety of promotional opportunities available, such as sponsorship and table top displays. Similarly, if you are interested in attending as a delegate and would like to be kept up to date with conference developments then please get in touch.

Terry Robinson, of XL Technologies UK Ltd, served as a board member, chairman, treasurer and a member of various sub-committees. Colin Dawson, of Whitelegg Machines Ltd, was a former chairman and elected president in 2012. Mr Robinson’s decision to retire from the board was strongly influenced by family duties. “I have enjoyed serving S S Terry Robinson, left, is presented with a gift on his retirement from the executive board 
by Paul Wright, boardmember The IWMA is delighted to announce that the 7 th biennial CabWire world cable and wire technical conference will take place on Tuesday, 3 rd November 2015 in Düsseldorf, Germany, home of the wire industry. CabWire Wor ld Conference 2015 3 N o v e m b e r 2 0 1 5 Congress Center Düsseldorf, Germany 7 th biennial cable and wire technical conference The conference will be held at the Congress Center, and is already attracting interest following the successful CabWire conference which was held at the Palazzo Turati, Milan, in November last year, and attracted 200 wire and cable professionals from all over the world. Preparations are well under way with Dr Probst, retiring CEO of

CabWire 2015 world technical conference – a date for your diary!

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HDT-X series high-speed auto-reel-change dual take-up

of automatic reel change that is suitable for large section cable. It adopts the distinct design of hydraulic driven scissors, which guarantee the achievement of this function. This kind of dual take-up features parallel positioning of two cantilever take-ups, which share one traversing mechanism driven by AC servo motor. The mechanical and electrical integrated impact design also saves space for the user. The advantages of high speed, continuous production and raw material saving are able to help cable makers increase productive efficiency and save manpower. Shanghai Kechen Wire & Cable machinery co. Ltd – China Email: yangchi1120@vip.163.com Website: www.kcmachine.com.cn Experience counts PW Hall Ltd, based in Glasgow, UK, is a leading manufacturer of colour and additive masterbatches for wire and cable compounds. With more than 30 years’ experience in this market, the company offers an extensive range of polymer specific masterbatches to colour the following compounds used in the wire and cable industry: LSZH, XLPE (Visico TM /Ambicat TM ex-Borealis/ Borouge), TPU, TPE and PBT. There is increasing concern, particularly in hotter countries, over cables fading in colour after outdoor exposure, and PW Hall offers a wide range of colour masterbatches incorporating pigments with excellent light stability and weathering properties to avoid colour fading after short term exposure. PW Hall has a well-established export business with an extensive network of overseas agents and distributors. PVC, PE, XLPE (Sioplas),

S S HDT-X series high-speed auto-reel-change dual take-up

is conventionally applied for small section cables. Facing the above demand in 2013, KC Machine developed a dual reel static take-up with the function

When continuous production of large section cable sheathing, it is obviously not feasible to realise automatic reel change on dual take-up by the method of uniformly cutting which it comes to

Successful show for Eder

interest in the ETC-1/HF and ETC-2 LS tungsten carbide die. All the machines are offered with the following advantages: • Large work range available • Perform all grinding and polishing operations • Processing of all die profile portions (cones and bearing) • High precision of dies achieved by an efficient control system • Easy to understand and operate • One operator required only to double output • Fast processing of all dies • Durable equipment concept with minimal maintenance cost Considering the high number and the remarkable value of precision dies in use in today’s highly competitive wire drawing industry, it is worthwhile to save and repair them by means of suitably efficient equipment, not to endanger the necessary overall economy.

S S The USP-TWIN ultrasonic machine from Eder

With over 65 years’ experience in the field of reconditioning wire drawing dies, Eder Engineering celebrated wire 2014 in Düsseldorf with four firm orders given on the stand, and 64 specified enquiries. More than 200 customers visited the stand during the week, embracing not only the ND/PCD die working equipment, the USP-TWIN ultrasonic machine and the HGM-21 wire-type sizing unit, but also showing great

Eder Engineering GmbH – Austria Email: info@eder-eng.com Website: www.eder-eng.com

PW Hall Ltd – UK Email: info@pwhall.co.uk Website: www.pwhall.co.uk

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Second Queen’s Award for innovative Metalube

Annual general meeting

The IWMA’s next annual general meeting will be held at The Mere Hotel, Manchester, UK, on Wednesday 4 th February 2015. As in previous years, the AGM will be followed by a members’ lunch – an ideal opportunity for members to network in a more social environment. For more information about the AGM, please contact the IWMA office.

A weekend in London – and dinner

S S The laboratory team at Metalube, from left to right, Lesley Hallam, Chris Nettleship, Kevin Duncan, Ben Clarkson, Naomi Pells, Wayne Thornhill and Beverley Gallifant

cap. To win the Queen’s Award once is a major achievement, but to win two years in a row is a superb honour. I am so proud of all our chemists who innovate on a daily basis. It is fantastic that their hard work and technical expertise is now acknowledged by this esteemed recognition.” Metalube manufactures lubricants and greases mainly for the wire and cable industry. The majority of households will own everyday appliances that use copper wire lubricated by the company, and its greases protect the overhead power cables that conduct electricity to homes. The experienced exporter employs 31 people and has offices in China, India and Brazil.

Specialist Metalube

lubricant

manufacturer

Here’s your chance to grab an entertaining weekend in London – and enjoy a night at the IWMA dinner dance at the Royal Garden Hotel, Kensington. The annual evening takes place on Friday 21 st November at this five-star hotel situated in the UK’s capital city. The association’s discount – previously available for up to four persons in your party – has now been extended to cover everyone in your party. No cancellations will be accepted after this date, but substitute names will be permitted; no refunds will be made for cancellations received after 26 th September. For further details please contact the IWMA office on +44 1926 834680 or visit the website at www.iwma.org The closing date for bookings is Friday 26 th September.

has a highly prestigious Queen’s Award for Enterprise for Innovation 2014. This is the second successive year that it has been honoured with this accolade. Exporting to over 86 countries worldwide, the company won in the International Trade category in 2013. An Innovation Award was made for inventing the synthetic grease OCG 6000 to protect overhead electrical conductors. The corrosion-preventing grease can operate at over 200°C with an operational life exceeding 20 years. OCG 6000 extends the lives of conductors and ultimately saves capital investments by delaying future renewal of pylon infrastructure. Chris Nettleship, technical director, said: “This is a great feather in our been awarded

Metalube Ltd – UK Email: post@metalube.co.uk Website: www.metalube.co.uk

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lune introduces slotted head for wire diameters up to 7mm

temperatures ranging between 10 and 250°C (50°-482°F) and offers a maintenance-free solution suitable for continuous operation. physically based on the detection of the convective heat flow by means of a heat flow sensor. In contrast to common optical IR-measurement systems, the lune CHF is independent of emission factors, colour, speed, surface structure and varying distances between sensor head and surface. The system is wear-free as there are no moving parts. Moreover, the lune CHF features an automatic calibration system, so the user only needs to set the reference temperature. further redeveloped the well-known Luxtron/ Ircon measurement system, which ceased distribution in 2008. The powerful lune CHF electronics are suitable for the connection of Luxtron/Ircon sensor heads, and lune Prozesstechnik offers global repair and calibration services for all CHF sensor heads manufactured by Luxtron and Ircon. lune also develops customised and industry-specific sensor heads. CHF measurement is With the CHF system, lune Prozesstechnik has

S S The lune CHF (convective heat flow) measurement system (here with slotted sensor head) records temperatures ranging between 10 and 250°C (50°-482°F) and offers a maintenance-free solution suitable for continuous operation without susceptible optics

the complicated threading of the wire and cable is eliminated,” said managing director Harald Boehnert. “With the capability of measuring wires with diameters up to 7mm customers benefit from increased flexibility and efficiency in their processes.” heat flow) measurement system, which is also available for profiles, cables, foils, pipes, rollers or belts, records The lune CHF (convective All these wire products have been exported worldwide for many years and are renowned for innovation, quality, service and competitive pricing. The South African Wire Association was created in 2002 to assist members to take part in global markets by creating an awareness of the importance and benefits of international trade for the members, the wire industry and to the South African economy. This is achieved by utilising all resources available within the industry and government through the South African Department of Trade and Industry, to promote sustainable growth

Germany-based lune Prozesstechnik has extended its range of slotted heads for the continuous temperature measurement of wires. Now capable of measuring wires with diameters from 0.2mm to 7mm (0.008" to 0.28"), the Wiretemp LC is equipped with four sensors and offers flexibility and increased productivity as compared to the closed version. “The slotted head can be easily and quickly assembled and mounted as SAWA on show The South African Wire Association and seven member companies took part at the South African National Pavilion at wire 2014, sponsored by the South African Department of Trade and Industry. South Africa is recognised as a reputable and stable trading partner of quality products and has a history of successful exports of wire rod, and value added downstream products such as wire of various qualities and grades, wire rope, strand, articles of formed wire, welded link chain, springs, nails, and manufactured items for agriculture, automotive, construction, mining, retail and security sectors.

lune Prozesstechnik GmbH – Germany Email: boenhert@lune-gmbh.de Website: www.lune-gmbh.de

and value for existing manufacturers and to facilitate entry into international trade by new industry entrants and emerging exporters. The membership base includes large, medium and small manufacturers who will be able to accommodate specific requirements from South African materials. All members are reliable and competent exporters who adhere to the Association’s code of conduct for international trade.

South AfricanWire Association – South Africa

Email: sawa@sawa.co.za Website: www.sawa.co.za

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New sales managers and regional realignment

S S Jesse Gallop, western district USA sales manager

S S MichaelSpurgin,southcentralUSAsalesmanager

S S Rafael Cairo, sales engineer for Brazil

new business development and sales growth. Mike Cooley, miidwest USA: Mr Cooley will continue to oversee the Kansas, Iowa, Missouri, Minnesota, Nebraska, and North and South Dakotas regions and will now cover northern Arkansas and northern Oklahoma. In addition, he will be responsible for the metals market sales in Illinois. He will work closely with partner Concept Machine Tool and its Metrology division to develop the plastic medical tube extrusion business in Minnesota. Brad Robillard, north central west USA: Mr Robillard assumes the regional territory responsibilities for Indiana, Kentucky, Michigan and western Ohio. Given the business opportunities in this region and the focus required to best serve key customers, he brings an exemplary track record of success in the sales of Beta LaserMike’s measurement and controls solutions. He will be a tremendous asset to the company’s base of customers in this region on many levels.

He will play an essential role in the development of sales programmes aimed at expanding the company’s footprint in this region. He previously worked as a sales specialist for the Keyence Corporation of America. Rafael Cairo, sales engineer for Brazil: Mr Cairo is responsible for developing business opportunities with existing and potential customers in Brazil. He will focus on delivering Beta LaserMike’s portfolio of measurement and control solutions for metrology, on-line gauging of rolled products, wire and cable, and plastic pipe and tube extrusion. He has several years, experience working for Keyence Brazil as a sales engineer supervisor, and previously worked for the equipment and pipeline division of Confab Industrial SA (Tenaris) as a sales engineer. The following sales managers and their regional territories have been realigned: Ethem Erdas, North Central Eastern USA: Mr Erdas will now be responsible for the region which includes eastern Ohio, West Virginia, western New York, and western Pennsylvania. He will work closely with Beta LaserMike’s network of agents and representatives to drive

Beta three new team members to its Americas organisation, as well as sales territory changes to certain regions. This organisational re-alignment is in line with the company’s on-going commitment to provide non-contact measurement and control solutions to its broad base of customers. The new sales managers will report directly to Bob Stockholm, director of sales for the Americas. Jesse Gallop, western district USA sales manager: Mr Gallop will be responsible for the market penetration of Beta LaserMike’s products and services with key customer accounts and target market segments. A key role will be working with the company’s channel partners to drive continued sales growth in this region. He has 25 years of sales and account management experience in analytical instrumentation, most recently working for Thermo Scientific as seniors engineer. Michael Spurgin, south central USA sales manager: Mr Spurgin is responsible for creating new business opportunities and managing customer relationships in South Arkansas, South Oklahoma, Louisiana and Texas. LaserMike has added

Beta LaserMike – USA Email: sales@betalasermike.com Website: www.betalasermike.com

Read all about it Please remember that member news stories can be published on the IWMA website at any time, so submit them to info@iwma.org as part of your company’s promotional campaign and they will be uploaded. Case studies are also being included so if your company enjoys a significant business win or provides a customer with a solution to a particularly difficult problem, then the IWMA would be happy to help spread the news for you.

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IWMA new members

Vinston US Corporation Vinston US Corp is the distribution and support centre for all Vinston products for North America. American owned and operated, it offers customers technical support, hands-on training and demonstrations. The Vinston product line is designed and integrated by top engineers educated in the United States and its machines are highly competitive in terms of quality, user friendliness, reliability, efficiency and cost. The Vinston brand is also rapidly expanding its customer base throughout Southeast Asia, Europe and South America. A Karpat Ltd In the late 1950s, Anthony Karpat moved to Canada to sell various hardware items to local retailers in the Montreal area. His goal was simple: combine the time-tested European tradition of supplying quality items at a fair price, and deliver them on time. This tradition continues today. More than 40 years on, A Karpat Ltd offers an extensive line of quality hardware products to major retailers, distributors and industrial clients in Canada and the US. Advaris GmbH As an independent software and consulting house, Advaris offers fully

India, the Middle East and Europe to customers’satisfaction. Fast Cables Ltd Since its inception in 1985, Fast Cables Limited has provided excellent customer service and affordability for the cable industry in Pakistan. The company’s emphasis on quality has made it a reputable business in the region, and a chosen supplier to electrical consultants, engineers and architects in the country. The manufacturing plant in Lahore is equipped with state-of-the-art technology along with an excellent quality assurance system. In addition to its current product portfolio, it manufactures electrical cables and conductors to cater to the specific needs of customers. FH Machinery FH Machinery has more than 400 machines at its warehouse and is able to locate machinery on a bespoke basis for customers. As a single source supplier for new and used fastener, cold forming and wire forming equipment, the company’s experienced sales staff can ensure customers are able to manufacture their products at the best possible prices.

integrated turnkey solutions from a single source. The autonomy of its software development allows the Advaris standard software to provide uncompromising industry-specific and customised business processes. For more than ten years both small and medium-sized companies and global leaders in the cable industry have placed their trust in Advaris and have been successfully using its software. Singhania International LTd Singhania International Limited has been involved in the ferrous and non-ferrous industries, steel and related products for over 40 years. Based in India, it specialises in manufacturing quality steel wires and supports a wide spectrum of market sectors, including fasteners, automotive, bicycle and other specialised applications. MPI Machines Ltd MPI was established in 1979 and promoted by MPI Machines Ltd. The company is located in the central part of India at Gwalior. With continuous development in the wire and power and telephone cable Industries, the company has developed import substitutes and successfully commissioned its machines at various cable factories in

Company

Country

Website

Vinston US Corp

USA

www.vinstonus.com

A Karpat Ltd

Canada

www.akarpat.com

Advaris GmbH

Germany

www.advaris.com

Singhania Int Ltd

India

www.singhaniainternational.com

Paramount Conductors Ltd

India

www.paramountconductors.com

MPI Machines

India

www.mpigwl.com

Fast Cables Ltd

Pakistan

www.fast-cables.com

Shaoxing Kaichen Mica Material Co Ltd

China

www.sxkcym.com

Gür Fil Sanayi ve Elektronik

Turkey

www.gurfil.com

South African Wire Association

South Africa

www.sawa.co.za

Australian Wire Association

Australia

www.wireassociation.com.au

Heinze & Streng GmbH

Germany

www.heinze-streng.com

FH Machinery

USA

www.fhmachinery.com

Shanghai Singcheer Technology Co Ltd

China

www.singcheer.cn

FS Cables

UK

www.fscables.com

Longcombe Labels

UK

www.longcombe.co.uk

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Air wipe efficiency

unit and assist breaking the surface tension of water. The 838 is effective at line speeds of up to 1,000m/minute. Marldon adjustable orifice air wipes have three sizes in the range, which can accommodate product diameters of up to 65mm. Made of stainless steel, they are effective at line speeds commensurate with most production line speeds. Two wheels are mounted to a sturdy support bracket; the lower wheel is stationary and the upper wheel hinged to facilitate loading and to allow the passage of lumps. Adjusting the orifice is accomplished by rotating the indexed wheels to the appropriate diameter marking on the circumference then locking them in place. Air is supplied at an ‘upstream’ angle only to the orifice through which the cable passes to efficiently provide maximum wiping action all around the cable. individual stations. The designer does not have to re-design the calculated shapes. Beneath top and bottom rolls, side rolls and accessory rolls can also be used. After finishing the roll design, a direct interface to FEA assures that the complete process of building the FEA model is done automatically within a few minutes. Made by hand, this would usually take more than one day. The simulation itself only takes a few minutes, so that the next optimisation step can be conducted in less than one hour. This means that a design can be optimised within one day – avoiding the most critical problems during the first setup as they could already be detected during the design stage. Marldon Group Ltd – UK Email : sales@marldon.com Website : www.marldon.com

orifice is adjustable, a wide range of product sizes can be accommodated with a single wipe. Other brands of air wipes use a fixed orifice, which is efficient for only one product diameter. Different units must then be used to optimally wipe the full range of product diameters manufactured on a single production line. All Marldon air wipes allow the passage of lumps by use of hinging mechanisms that open to allow lumps through, and then close back when they have passed. Marldon air wipes are constructed of durable materials, including stainless steel, aluminium and ceramics, depending on the model. The model 838 is a high-speed air wipe for small products up to 8mm in diameter. Multiple air jets provide maximum wiping action. The spring-loaded upper assembly will lift allowing easy threading and the passage of lumps. Wear-resistant ceramic inserts prolong the life of the

S S High-speed air wipe model 838

Following the extrusion process, air wipes are used to remove cooling water, either droplets or films. Wiping is necessary to ensure proper operation of such equipment as spark testers, in-line printers and dimension gauges. Marldon air wipes achieve maximum wiping action because the wipe orifice can be easily changed to the optimum diameter for efficient water removal for a given product diameter. Because this

Profile wire rolling design and simulation – an integrated Finite Element Analysis is a widely accepted tool to check a design prior to manufacturing. For example, the automotive industry makes use of the technology to improve its products with great success. Due to its complexity, the rolling of profile wires is a challenge. FEA solutions are available, but this is only half of the story. To be able to perform an effective design optimisation, a powerful design tool and a seamless integration in FEA are also necessary.

The Copra ® RF WireRolling solution from data M supplies all these demands. The design provides the necessary possibilities to define the shaping steps – manually, automatically or by combining both; the grade of deformation and the compression can be defined by the operator; and the calculation of the shape and of the cross-section area is done by the system. All relevant information is shown in a table; changes will update the geometry instantly. The integrated definition of the machine data allows entering of the axis positions. The contour of the forming rolls is directly extracted from the profile shape in the

data M Software GmbH – Germany Email: datam@datam.de Website: www.datam.de

S S Copra® RF WireRolling design software from dataM

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